Assembly

Assembly S5-42 ZF





1. Place input shaft and synchronizer ring assembly over tapered roller bearings on input end of mainshaft.

Meshing Mainshaft And Output Shaft:

2. Place mainshaft and input shaft on gear pack holding fixture, tool No. T87T-7025-HH or equivalent.






3. Place countershaft on fixture, then mesh gears of two shafts.






4. Place three shift rails and fork assemblies into shift rod support, tool No. T87T-7025-HJ or equivalent in their original position.






5. Position three shift rail assemblies together with the shift rod support tool and interlock so that the shift forks engage in the correct mainshaft sliding sleeves.






6. Place shift interlock on three gearshift rails, then engage it in interlock grooves in 5th/reverse (upper) rail.






7. If equipped slide speedometer worm gear onto mainshaft until it seats against stop on mainshaft.






8. Secure rear cover into bench mounted holding fixture T57L-500-B or equivalent.
9. Position Nylon Lifting Sling. D87L-1000-A or equivalent around the shift rails, the holding fixture and the mainshaft and countershaft. Position the gear pack into the rear case and push the shafts and rails forward until the bearings seat in their outer races in the housing and the gearshift rails slide into their retaining holes in the housing.






10. Rotate gear pack and rear case upwards 90° so it is in a vertical position with the input shaft pointing upwards.






11. If equipped slide output flange onto the output end of mainshaft until it seats against its stop. Screw hex nut onto shaft until finger tight.

CAUTION: Use care to ensure mainshaft bearing is not pushed off its race when flange is installed.






12. Remove shift rod support tool from ends of shift rails.






13. Remove strap, then the gear pack holding fixture from mainshaft and countershaft.






14. Attach three cap screws that secure shift interlock to rear transmission housing. Torque cap screw to 10 N.m (7 ft lbs). Be sure that the interlock moves freely after tighting the screws.






15. Engage teeth of reverse idler gear with reverse gear on mainshaft, then slide reverse idler gear shaft downward through bearings and into rear case.
16. Align lower of two threaded holes in shaft with bore with rear case.
17. Place a sealing ring on the capscrew and attach the screw through the bore in the housing into the shaft. Tighten the screw finger tight.











18. Insert the central shift rail and finger assembly into its bore in rear case. If the magnet was removed during disassembly, insert it in the housing.


19. If necessary, perform adjustment procedures, then apply a suitable sealant to rear case. If front case, rear case, countershaft mainshaft input shaft, or any bearing required replacement, tapered roller bearing adjustment is required.






NOTE: Do not wait longer than ten minutes to tighten all 17 bolts, due to the rapid curing time of sealant.

CAUTION: Do not use silicone Sealing Compound or equivalent.

NOTE: the tapered roller bearings preload should be adjusted if either the front or rear cases, countershaft, mainshaft, input shaft or a bearing has been replaced. If the tapered roller bearings on the mainshaft, input shaft or countershaft have to be adjusted, do not apply the sealant at this time.






20. If removed, push three shift rail detents back into their holes in front case.

CAUTION: Use care to ensure shift rail detents do not obstruct entry of shift rails.






21. Carefully place from case over shafts and gearshift rails until it rests on its mating surface of rear case. If necessary to facilitate installation of front case, push central shift rail inward to clear inner surfaces of front case.

CAUTION: Be careful that input shaft does not damage the front seal. Also be careful that the shim pack oil baffle is not bent when the case is positioned over the input shaft.






22. Drive in two dowels that align rear case and front case, then insert and finger tighten two hex screws.
23. Insert and finger tighten two additional hex screws into rear bores.






NOTE: If it is not necessary to adjust the mainshaft/input shaft preload. Install all of the hex screws that attach the two cases and tighten to 25 N.m (18 ft-lb).

CAUTION: Adjustment of tapered roller bearing preload is necessary if either the front or rear cases, countershaft, mainshaft or input shaft has been replaced. or if a tapered roller bearing on either shaft has been replaced. Refer to adjustments in this section for tapered roller bearing preload adjustment procedure before continuing assembly procedure.






24. Fit sealing ring to the reverse idler shaft retaining capscrews. Install the screws into their bores in the front and rear cases and tighten to 22 N.m (16 ft-lb).

25. With a screwdriver push caps into the capscrews until they are flush with the surface of the screw head.

CAUTION: Use hand pressure for screwdriver only, Do not hammer caps into position.

26. Rotate transmission, input shaft down, then install speedometer drive gear on mainshaft.
27. On 4x2 models, remove output flange to mainshaft hex nut, then the flange from shaft. Position output shaft seal on output shaft seal replacer tool No. T87T-70925-BH or equivalent, then place seal and tool in opening in rear case. Using a soft hammer, gently tap seal in until it seats in opening. Apply a suitable liquid soap solution around circumference to minimize friction.

Installing Rear oil Seal:

28. On 4x4 applications, install output shaft oil seal using shaft seal replacer tool No. T87T-7025-LH and seal installer tube tool No. T77J-7025-B or equivalent. Gently tap on tube using a soft hammer until tool seats against stop.






29 On 4x2 applications, reinstall the output flange on the output shaft. Install Companion Flange Holder T78P-4851-A. Install the hex nut onto the mainshaft using locknut socket Tool T87T-7025-AH. Tighten the nut to 250 N.m (184 ft-lbs).







30. On all models, secure locknut by bending tab on nut into mainshaft.






31. If required, install new gaskets and PTO covers over openings in front case, using the original attaching screws and torque to 38 N.m (28 ft lbs).
32. Position 5th/reverse gear interlock plate into its installed position, then place gasket over shift tower mating surface in front case.
33. Ensure stop plate moves freely and no interference from gasket is present. Use care that interlock plate or spring does not drop into front case.
34. Check interlock plate compression spring against Spring Specifications at the end of this Section to be sure that its unload length is satisfactory. See step 39.

Installing Interlock Plate:

35. Place spring above nose in interlock plate, then move both parts into their installed positions. Ensure interlock function between 5th gear and reverse gear operates properly.






36. Install shift tower assembly, ensuring nose on gearshift finger points towards interlock plate.
37. Install spring washers, then torque screws to 25 N.m (18 ft lbs).






38. Check operation of interlock. Shift lever cannot be shifted between 5th and reverse if interlock is properly installed. Do not force lever to shift into reverse. Damage to the interlock components could occur.

Installing Compression Spring:

39. A compression spring is installed over each of the three detent bolts. The positions are shown in the illustration. Before installing the springs, check that their unloaded length is 44.1mm (1.736 inch).






40. Install cap in each bore in front case where detents, bolts and springs were installed. Use a suitable drift or punch to drive each cap in until it seats 1mm (3/64 in.) below the surface of the housing.






41. If removed, install the back-up lamp switch with a new sealing ring into its mounting boss on the side of the front case near the transmission nameplate. Tighten the switch to 20 N.m (15 ft-lbs).

Bearing Preload Adjustment
Measurement and adjustment of the tapered roller bearings is necessary if a housing, countershaft, mainshaft or input shaft has been replaced or if a tapered roller bearing per shaft has been replaced. The mainshaft to provide a preload of 0.00079 to 0.00434 inch (0.02 - 0.11 mm). After adjusting the two shafts, each should be rotated a few times to center the rollers in the bearings involved.






Input Shaft and Mainshaft Tapered roller Bearing Preload Measurement
1. With the transmission placed on a bench with the output flange facing upward, attach a dial indicator gauge with a magnetic base, Tool D78P-4201-B (or equivalent) to the output flange in such a manner that the measurement bar will rest on the output end of the mainshaft as shown in the illustration.
2. Zero the dial indicator and, using a pry bar, gently pry up the input shaft and mainshaft.
3. Mote the dial indicator gauge reading. A shim and baffle which is to be fitted later must have a combined thickness equal to the dimension recorded on the dial plus 0.00079 to 0.00434 inch (0.02 to 0.11mm). This will result in obtaining the specified preload after installation of the shims and shaft seal, and mainshaft and countershaft.

NOTE: Shims and baffle must be removed prior to preload measurement. The baffle is part of the shim package under the bearing race.

Countershaft Tapered Roller Bearing Preload Measurement

1. Using two 1Omm hex screws, attach Dial Indicator with Bracketry TOOL-4201-C or equivalent, the P.T.O. opening in the front case as shown in the illustration. Position the dial indicator gauge to the support in such a way that the measurement bar rests against the flat face of the four speed helical gear on the countershaft.
2. Set the dial indicator needle to zero.
3. Insert pry bars through each of the two power take-off openings and position them beneath the 4th speed helical gear on the countershaft. Pry up on the countershaft.






4. Like the preceding shaft check, the preload should be 0.02 to 0.11 mm (0.00079 to 0.00434 inch) after installing the shim.

Mainshaft and Input Shaft Tapered Roller Bearing Preload Adjustment






1. After completing the tapered roller bearing preload measurements described previously, place the transmission in an upright position with the input shaft pointing upwards.
2. Drive the two dowel pins out of their holes in the front and rear cases and lift the front case off the rear case.






3. Using Slide Hammer T5OT-1OO-A or equivalent and Internal Puller D80L943-A or equivalent, remove the countershaft and mainshaft tapered roller bearing outer races from the front case.






4. Fit each race with a shim washer or shim washer and baffle plate to obtain the required preload determined previously. Gountershaft preload is established by using shims alone; input shaft and mainshaft preload is established by using shims and a baffle. In both cases the parts are installed beneath the outer race of the tapered roller bearing which seats in the front case.

NOTE: Always replace the baffle plate with a new one when removed.

5 Apply Gasket Maker E2AZ-19562-B (ESE-M4G234-AZ) or equivalent to the mating surfaces of the front and rear cases.

CAUTION: Do not use silicon.

Position the front case on the rear case. Install all of the screws that secure the two front and rear cases and tighten to 22 N.m (16 ft- lbs.).

Synchronizer Ring/Synchronizer Body Wear Check






Position the synchronizer ring on the synchronizer body as shown in the illustration. insert a feeler gauge and measure clearance at two opposite points. If clearance is less than O.6mm (0.024 inch) for the 3rd-4th, 1st-2nd and 5th synchronizer assemblies and 0.4mm (0.016 inch) for the reverse synchronizer assemblies, replace the synchronizer ring, synchronizer body, or both if required to bring to within specification.

Synchronizer Compression Spring Tension Check






Check the length and tension of all compression springs of synchronizers.